Woven pile fabric



R. R. MATTHEWS 2,794,449 WOVEN PILE FABRIC Filed Jan. 28, 1954 $9.2 mma/af//cmf/asrcm nos/a7' www' z/P 0f aros/or mw UP pair/v 500735 I 5 lj I 5 l 1 I "n" au mmv arl/mmm fle-aow' foar faam agg /syzswr up .nauw ap INVENTOR @maior wmv uP up @ma @www .WW my up. @y M f'du/ ATTORNEYS WOVEN PILE FABRIC Russell R. Matthews, Cornwall, N. Y., assignor to Firth Carpet Company, Inc., New York, N. Y.

Application January 28, 1954, Serial No. 406,650

Claims. (Cl. 139-401) The present invention relates to woven pile fabrics of the kind used as carpets and rugs, and more particularly to woven tuft carpeting such as is produced with power looms.

It is the general object of this invention to provide a woven tuft carpeting having a novel backing construction.

More specifically, the object of the invention is to provide a woven tuft pile fabric that has more exibility, has a more tightly woven and substantially at backing layer aording a saving in backing coating material, and that has a iirmness of texture exceeding that of previously known weaves.

In the accomplishment of these objectives with their attendant advantages, a woven tuft pile fabric is formed which comprises a plurality of double weft shots in a common lower level, a plurality of double weft shots above alternate lower level double weft shots, a double warp chain binding together the lower level double weft shots, pile tuft elements looped under each upper level double weft shot, and a single binder warp lying alongside each double warp chain and extending over the upper level double weft shots and under the alternate lower level weft shots to bind together all the weft shots.

In a modified embodiment, similar objectives are attained, but to a lesser extent, by using a single Warp chain in place of the double warp chain, and a stulfer warp intermediate the loops of the pile elements and the single warp chain.

The details of construction and procedure involved in producing the novel weave pile fabric yembodying the principles of this invention will be more fully understood from the following descriptions of a preferred embodiment and of a modification thereof, when taken in connection with the accompanying drawing, in which:

Fig. l is a longitudinal diagrammatic view showing a section through a tufted pile fabric made in accordance with this invention, with a correlation of the shots made in weaving the same;

Fig. 2 is a table of heddle positions for the weaving cycle utilized in producing the fabric of Fig. l;

Fig. 3 is a longitudinal diagrammatic view showing a section through a somewhat modified woven pile fabric embodying the principles of this invention;

Fig. 4 is a table of heddle positions for the weaving cycle utilized in Fig. 3; and

Fig. 5 is a longitudinal section view showing the intermingling of the pile tufts of a pile fabric embodying this nvention.

In the woven tuft fabric shown in Fig. l, a plurality of double weft shots extend horizontally in closely spaced relation in a common lower level, and a plurality of double weft shots 12 extend horizontally in a common upper level in vertical alignment above every other, or alternate, double weft shot 10 in said lower level. A double warp chain having a front chain 14 and a rear chain 16 binds the double weft shots 10 of the lower level in the assembled relation shown. A pile tuft ite States Patent ICC element 18 having a pair of upstanding legs is looped under each upper level double weft shot 12. A single warp 20 extending behind and against the rear chain 16 of the double warp chains of the fabric passes over each upper level double weft shot 12, thus binding the weft shots 12 and the pile tuft elements 18 to the lower level double weft shots 10, held by the double warp chain 14-16.

The wefts of the above-described fabric may be of jute or the like, the double Warp chain may be of cotton or linen, as is also the single binder warp, and the pile yarn of the tuft elements is preferably made of a pair of singles wool or wool blend yarns. The pairs of singles are so plied together and of such relative twist and twist direction as to cause the tuft legs to separate, bend, and incline themselves in random directions. 'Ihus maximum coverage is provided without sacrifice of desired stiffness. Such a pile construction having tuft legs with a high twist component plied with a low twist component has been previously known and. used commercially in other weaves.

Other pile yarns such as regular hard twist yarns, ordinary balanced twist yarns, novelty knitted yarns, novelty nub yarns, novelty slub yarns, and all combinations of these also may be used in the reed, checkerboard effect, and in various other regular pattern effects.

The method of weaving the woven tuft fabric of Fig. l is indicated in the table of Fig. 2 tabulating the heddle positions per cycle. The first shot, second shot, and third shot of the cycle as set forth in the table correspond to the shots of the same number marked above and below the fabric weave of Fig. 1.

Although, for clarity of illustration, the single binder warp 20 is shown as extending below the lower plane ldefined by front and rear warp chains 14 and 16, in the finished fabrics it lies in substantially the same plane. lt will also be understood that the actual fabric is of tightly woven construction.

While in a conventional Weave the pile tufts take a U or a V shape and stand in solid rows, in the novel weave of this invention the pile tufts of adjacent rows overlap and intermingle as clearly indicated in Fig. 5, wherein the tuft elements 18 and the double weft shots 10 and 12 correspond to the parts similarly designated in Fig. l.

It will now be apparent that the novel arrangement of the double weft shots in close relation in a common lower level or plane results in less space to be filled by the backing coating material, that the double chain warp elements for these lower level double wefts insure tight binding, and that the single binder warp 20 passing over the spaced double weft shots in the upper level securely binds down the loops of the tuft elements and enters the backing between the double chains, to improve the strength and firmness of the nearly at backing surface.

These advantageous results have been attained with but very little increase in binder Warp material, and without appreciably complicating the weaving operations.

Since the modified embodiment of the invention illustrated by Figs. 3 and 4 closely follows the preferred embodiment which has been described in detail, the modification will be described more briey with ernphasis only on the points of difference. These differences are concerned with relative rearrangements of the three warp elements.

As shown in Fig. 3, closely spaced, double weft shots 30 lie in a common lower level plane, and widely spaced double weft shots 32 define a common upper plane and lie in vertical alignment with every other double weft shot 30. A stuer warp 34, which may be of cotton or the like, extends intermediate the upper level of a single chain warp 36 and the loops of pile tuft elements 38, which pass under the upper level weft shots 32. A single binder warp 40 extends between the chain warps 36,

y immediately behind the stuier warp 34; and`passes under every other pair of lower level wefts 30 and over every pair of upper level. wefts 32 to bind the weftsfS-Zcaud the pile tutt elements' 3'8" to the lower level.- wefts. 30,. and *the* alternate lower level. weft/s. 3'0. to: the chain warp.. 36;

While this modified: construction.V is not quite as tightly woven,. it possesses a. substantially level backing.. surface with. reduced space for' receiving excess coating,material;` andarm texture. of goodexiblity and strength.v Y The weaving procedure for the modiiied construction ist clearly indicated by the correlation of. the: table. of

Fig.v 4^@ with the. correspondingly numbered shot shownabovev and below, Fig. 3,.it being; noted thatthe.- principal.

diterenceis nthe position of. front-y heldle` in therst shot..

Whileapreferred embodiment. and one modification oithewoven pile fabric. of. thisinventionz havey been. described in detail, it will-.beunderstoodthat variations and changes can: be. made: inweaves. without. departing. from the principles of: thel invention and the scope oi'the ap.- pendedV claims.

Having, thus: describedv my invention.V whatE L claim asv novel and desire to secure by Letters Patent of. the United Statesr is:

l. A woven pile fabric comprisinga pluralityof closely spaceddoubleweft shots in a-.commo'n lower level, a. pluralityf of double weft shots disposed in a common upper:

level above alternate lower. level doubleY weft shots, aVV

double warp-chainbindingtogether therlower levelxdou'ble weft shots;` pile tuft elementsy looped under each upper level double` weft shot-,and'a single binder warp: adjacent each: double warpchaint extending; over the upper level? double weft shots and: under the: alternate. lower level weft shots.

V2; Ai tightly packedpilev fabric comprising a; plurality oclosely spaced double weft shots in axcommon. lower.

level, a plurality of. double weft shots disposed in' a` common: upper levelinzverticall alignmenti above: alternate lower level double weftshots; a; double warpchain bind. ing together the lower level double weft shots, pile` tuft; elements looped imdei: each; upper level; double weftV shot,

and a single' binder warp' lyingY alongside eaehdoubleA warp chain andV extending: over: the: upper levelA double weft shots andunder the alternate lower: level weft4 shots.

3. A woven-.pile fabriecomprising alplurality, of. closely spaced. d'ouble weft shotsin; a'. common lower leveL. a plurality of doubleweft slrotsfdisposedimaconunon. upper level-above.- alternate lower level double weft. shots; pile over the upper. level double weft shots and under the alternate lower level'v double weft shots.

4. An Axminster carpet weave comprising a plurality of doubleweftfshots-inacommon lower level, aplurality of double weft shots disposed in acommon upper level above alternate lower level double weft shots, pile tufts looped under each upper level double weft shot, a warp element extending under the lower level double weft shots that are beneath the pile tufts: andv over the lwer level doubley weft` sliots intermediate thelpile tufts," anotherV warp elementextendinggbelw the looped-portions of the pile tufts and above the lower level double weft shots beneath said, pile tufts, and a binder, warp. disposed: adjacent both4 of the said two warp elements and passing over the upperV level double weft shots and under they lower level. double weft shots therebetween.

5. A wovenpilefabric comprising a plurality of double weft. shotsina-.common lower. level', a plurality of double weft` shots. disposed in a common upper level above alternate lower leveldouble weft shots,.pile tuft elements looped under each upper level double weft shot, a warp element; extending. underthe lower leveldouble weft shots that are beneath the pile tuft elements and over the lower level double weft shots intermediate the` pile tuft` elements,. another-, warp. element extending.. below' the looped: portions. orf-gthevpile tuft'elementsl and` above the lower level double weft. shots beneath saidpile tuft elements, and a binderwarp passingfover the upper level:

doubleV weft shots.- andA under the alternate lower level doublet weft. shots.

ReferencesCtediilthelefof thispatent Y UNITED PATENTS- 1,341,.4'I7' Davis May 25; 192()l 1.991,179 Shuttleworth Feb. 12', 1935 FOREIGN PATENTS` 7,205 Great Britain of 1905 5lg,9'92 Great Britain Mar. 13, 19'40 

